Innovating Aluminum Aerosol

ALL ABOUT ReAl®

Revolutionary Aluminum Aerosol Technology

A few years ago, Ball introduced ReAl® - a proprietary and patented technology. By developing a new alloy composition, Ball increased the strength of the aluminium used in aerosol can manufacturing. The increased strength allows for significant lightweighting of aerosol cans while preserving package integrity requirements.
The lightweighting provides cost and environmental benefits, such as a lower product carbon footprint and using less aluminium. The original ReAl, which replaced the standard aluminum aerosol can, was an 11 percent lighter package.

In 2015, Ball continued its aluminum aerosol lightweighting journey with the introduction of an even lighter iteration of ReAl in collaboration with Henkel Beauty Care. This newest iteration is now 15 percent lighter than the standard aluminum aerosol can. Additionally, despite the increased alloy strength, Ball successfully developed a container with a deep shape to produce a can with a distinctive shelf presence. Ball is working to achieve even further lightweighting in the future.

For a 150- and 200-milliliter sized can, Henkel's Fa is now the lightest commercially available can in the market. By utilizing the lighter weight ReAl technology, Ball estimates a product carbon footprint reduction of 12 percent, which saves the equivalent greenhouse gases emitted by a vehicle driving around the earth more than a thousand times (based on estimated annual volumes supplied).

"ReAl is a material that is stronger, formable and compatible with Ball's existing aerosol can lines," said Dan Rabbitt, vice president, Ball Aerocan. "For companies like Henkel, who continually drive for more sustainable packaging, this means that they can achieve their goals without sacrificing design or shelf presence. Everyone wins with ReAl – the customer, the consumer and the environment."